TWI609788B - Deep draw method of making impact and vibration absorbing articles and the articles formed thereby - Google Patents

Abstract

The present invention relates to cushioning elements, methods of manufacture, and methods of use, and more particularly to cushioning elements comprising a plurality of spaced apart pillars having a polymeric material.

Description

Deep press forming method for manufacturing impact and vibration absorbing articles and articles thereof

The present invention relates to a method of producing a polymer article and articles made therefrom, and, in particular, to a method of producing a polymer article having improved cushioning properties and articles made therefrom.

Many different types of products benefit from the inclusion of materials that provide cushioning of shock and vibration suppression in other things, compression, deflection, friction reduction, and other resistances. For example, many frequently used objects contain materials that are hard to touch and/or that cause friction, particularly repetitive motion, when placed against the body. In order to make the user more comfortable in use, for example by reducing stress and/or friction, it is generally desirable to make the body contact area of such objects as soft as possible.

Many attempts have been made to make such objects or body contact areas of such objects more comfortable for the user. One common type of cushioning material currently used in a wide variety of applications is open cell foam. Although the open chamber of the foam can capture debris and moisture, it provides growth of microorganisms such as bacteria and fungi. Thus, while open cell foams provide adequate cushioning for many applications, the propensity to provide bacterial and fungal growth makes it less suitable for applications that contact the body, such as footwear, sports pads (sprots). Helmet linings, medical pads and braces, seatings and more. Furthermore, depending on the application, in order to achieve the desired level of buffering, it is necessary to use relatively thick and/or dense open cell foams. As the thickness and/or density of the foam increases, its weight also increases, thereby further limiting the applicability of the open cell foam as a type of cushioning material. Furthermore, in the case of an object having a non-planar and/or complex shape, it is difficult to trim the shape of the cushioning material to conform to the shape of the object.

There is a need for techniques for improving impact and shock absorbing articles and methods of manufacture.

The invention herein discloses an embodiment of a cushioning element comprising a multilayer material having an insulating layer, a polymeric material layer disposed adjacent to the insulating layer, and a stabilizing layer disposed with the insulating layer Adjacent and opposite. A plurality of pillars are disposed within the multilayer material. Each of the plurality of pillars comprises a thickness. A plurality of spacer regions are also disposed between the plurality of pillars. The plurality of spacer regions comprise a thickness of a spacer region. The thickness of the pillar is greater than the thickness of the spacer region.

Another embodiment of the present invention is a cushioning member comprising a multilayer material having an insulating layer, a polymeric material layer disposed adjacent to the insulating layer, and a stabilizing layer disposed adjacent to the insulating layer Layer and opposite. A plurality of pillars are disposed within the multilayer material. Each of the plurality of pillars comprises a ratio of thickness to width greater than or equal to about 0.125 to 1.

Still another embodiment of the present invention is a method of molding a cushioning member comprising disposing an insulating layer on an upper surface of a first molding zone, the barrier layer comprising a thermoplastic elastomer (TPE) material Having a thickness greater than or equal to about 0.004 inches, under the influence of a vacuum, pulling the barrier layer against the surface of the first molding zone; dispensing a first portion of the polymer precursor onto the barrier layer; a stabilizing layer on the precursor; a second molding zone disposed on the stabilizing layer; and curing the precursor to form a cushioning element.

The present invention relates to a relatively inexpensive molding method comprising a cushioning material of different hardness and an article made by the method. The method unexpectedly produces a material comprising a plurality of pillars having a thickness of up to about 3 inches or more, and the spacer region between the pillars can be as narrow as about 2 inches (0.002 inches). And the thickness of the spacer region can be as low as about 0.005 inch. It has previously been considered that the aforementioned relatively high thickness and relatively narrow spacing are not possible. This method can be used to form a sheet comprising the previously separated pillars that can be cut to conform to the shape of an existing product. Alternatively, the method can be used to mold a variety of consumer products, such as inner soles, comprising the previously separated pillars.

The size, shape and contour of the pillars, the spacing between the pillars, and the materials disposed within the pillars can be designed to provide shock suppression, impact absorption, friction reduction, and cushioning. It can be varied as needed or necessary to achieve the desired product characteristics. In particular, the height or thickness of the pillar, substantially a combination of orthogonal sidewalls and an upper edge having a radius, provides the column with sufficient flexibility to be able to move in all directions for a substantial Impact absorption and vibration suppression. The spacing between the pillars allows the pillars to move independently, and the material between the pillars can be bent and flexed as desired. Due to the spacing between the pillars, the material between the pillars can also be bent and flexed, enabling the spacing region to function as a pivot and enabling the material to conform to a non-planar surface. (eg the inner surface of the helmet). The desired spacing can be determined by the desired amount of bending and/or flexing, as well as issues such as weight reduction, uniformity, and cushioning type.

The column is capable of dispersing impact and vibration by flexing or moving to the left and right sides. The amount of deflection of the column increases as the ratio of the height (or thickness) of the column to the width of the base of the column increases. When the height of the column associated with the width of the column base is reduced, the amount of deflection will be closer to the amount of material deflection of a plate. Thus, a taller and narrower column made of the same material can have a greater degree of deflection than a shorter and narrower column. The ratio of the height of the column to the width of the base of the column may range from about 0.125:1 to about 8:1, more specifically from about 0.25:1 to about 6:1, and still more particularly from about 0.50: 1 to about 2:1. It is also possible that the column is deflected to a lower ratio than previously described.

By providing pillars having substantially vertical sidewalls, the spacing between the pillars can be reduced while maintaining the ratio of the large height to the width of the substrate. For example, a pillar having an outwardly sloping sidewall has a wider base than a pillar having a vertical sidewall. In order to achieve the same ratio of column height to column substrate width, there are pillars with outwardly sloping sidewalls that are taller than pillars with vertical sidewalls.

In other embodiments, the pillars may comprise sidewalls that are substantially non-perpendicular, for example, having a width that is less than the width of the upper surface of the pillar or a width of the serrated portion or undercut of the pillar. The pillars contain such zigzag portions or undercuts that have greater flexibility than vertical sidewall pillars.

This method entails molding a polymeric material to form the aforementioned cushioning material having spaced apart pillars. It will be understood that the method is not limited to polymeric materials and that other materials that are not polymeric materials (e.g., synthetic materials, foams, and others) can be molded by this method. This method is particularly useful for molding relatively low viscosity or low durometer polymeric materials, such as polymeric gel materials, especially viscoelastic polymeric materials (hereinafter "gels"). Gels have relatively low hardness, such as viscoelastic gels, which can be very viscous, making them difficult to use (or impossible to use) in commercial process techniques, such as injection molding, because the material adheres to the mold.

1-12 illustrate, when placed together, an exemplary method for forming an article comprising the foregoing pillars in accordance with the teachings of the present invention. The method entails selecting a suitable mold 10 for the desired product, as shown in Figures 1-2, which may include opposing upper and lower surfaces 12, 14. As illustrated, the mold 10 may include a recessed region 16 at the top of the mold 12 defined by a surface which is recessed a depth D ₁ from the surface 12 downward. The names "bottom" and "top" and/or "above" and "below" as used herein are understood to be convenient for description and are not limited to any location or spatial location unless otherwise noted. Also, the names of "first" and "second", and others, are not meant to represent any order, quantity or importance, but rather to distinguish one element from another element, and the name "a", This does not represent a limitation of quantity, but rather represents the existence of at least one reference item. Further, the technical and scientific names used herein have the same meaning as commonly understood by those skilled in the art, unless specifically defined.

The exemplary mold 10 of the present invention comprises two (2) individual mold units 18 defined by recessed regions 16, each unit being in accordance with the shape and size of the desired final molded article, in this example a shoe Inside the pad. Although, for convenience, it is shown here as a shoe inner pad, it will be appreciated that the method is capable of molding a wide variety of products. Each of the two (2) individual mold units 18 includes a plurality of cells 18a separated by 16a. Each of the cells 18a includes a base 18b and a side wall 18c extending substantially perpendicular to the base 18b and the upper surface 12 of the mold 10, with an extended radiused edge "R" between the base 18b and the side wall 18c. This radiused edge "R" assists in providing impact and shock suppression of the final product. Each chamber 18a is recessed a depth from the upper surface down to D _2, the depth of which is to be in accordance with the thickness of final molded products. The chamber 18a can comprise different shapes, sizes and contours as desired or necessary.

The mold 10 may also include a gasket recess 23 disposed between the recessed region 16 and the periphery P of the mold 10, and a gasket 20 may be disposed in the recess. Alternatively, although not shown here, the gasket may be provided directly to the upper surface 12 of the mold 10. The gasket 20 can provide containment sufficient to prevent flow of polymeric material in the mold 10. The gasket 20 or mold 10 can include a periodic liner opening 22 (see FIG. 1) such that trapped air can flow out of the mold 10 during the molding process. Alternatively, the mold 10 can include one or more nesting guides 24 (eg, pins, stubs, and others).

As shown in Figure 3, after selecting a suitable mold 10, the method includes providing a barrier layer to the mold. When desired, the mold and/or the barrier layer 26 may be preheated (e.g., using radiant heat) and evacuated (e.g., about 5 to 15 pounds per square inch) to more closely attract the barrier layer 26 to The mold surface, which can result in a desired relatively thick pillar, or when the article requires more definition (eg, when they include features like undercuts and others). The spacer layer may be preheated prior to or after being disposed on the mold 10 using a variety of techniques including, but not limited to, radiant heat, heat transfer, and the like. In addition, preheating and/or vacuum can be applied throughout the molding process as needed. The barrier layer may be disposed on the mold 10 as a sheet material or as a coating layer directly on the mold. When used as a plate, the barrier layer 26 can be laid over the mold in direct contact with the gasket 20 such that it conforms to the outer shape of the mold 18 and the individual cells 18a. When used as a plate, the barrier layer 26 can also include a collar guide 24 (eg, a hole, a perforation, and the like) corresponding to the collar guide 24 in the mold 10 in order to assist the sleeve guide. It is aligned with the mold 10 and its subsequent layers. When the spacer layer 26 is not provided as a plate, it can be directly disposed on the upper surface 12 of the mold 10. A release coating layer (not shown) may be used to assist the release of the release layer 26 from the upper surface 12 of the mold 10, if desired.

As shown in FIG. 4, after the spacer layer 26 is disposed on the upper surface 12 of the mold 10, a polymeric precursor 28 can be distributed over the spacer layer 26. As used herein, "polymeric precursor" refers to a polymeric precursor material that has not been polymerized to form a polymer, including "foamed foam" polymeric materials well known in the art. The precursor 28 can be disposed over the barrier layer using, but not limited to, various types of techniques (eg, cast, injection molded, and/or the like).

The distribution of the precursor 28 may comprise casting a sufficient amount (e.g., volume) of the precursor to fill each of the two (2) individual mold units 18 instead of filling a single mold unit 18, as with other processes, such as injection molding. . For example, other methods, such as injection molding, require that the precursor 28 be separately distributed to each mold unit 18. Therefore, using the mold requires two (2) separate dispensing steps. In contrast, the method can include distributing the precursor 28 over the isolation layer once (eg, a single "casting"), and the distribution of the single precursor 28 can provide an amount of sufficient precursor, in a single All of the mold units 18 are formed under the secondary molding cycle. Distributing the precursor 28 in bulk (not individually) can substantially reduce the manufacturing time of the method as compared to other methods.

As shown in FIGS. 5 and 6, after the precursor is dispensed onto the spacer layer 26, the stabilization layer 30 can be disposed on the precursor, for example, a plate. When the mold 10 includes a collar guide 24, the stabilization layer may also include a corresponding sleeve guide (not shown) to assist the sleeve guide in alignment with the mold 10 and its subsequent layers. Positioning the stabilizing layer on the precursor may include disposing a portion of the stabilizing layer 30 over a portion of the precursor 28 such that an interface 32 exists between the precursor 28 and the stabilizing layer 30. Placement of the stabilizing layer 30 over the precursor 28 can be performed manually using a tool such as a roller 27, as shown in Figure 5, or the process can be automated. The remaining portion of the stabilizing layer 30 over the remaining portion of the precursor 28 can be advanced by applying pressure to the stabilizing layer 30 after the interface 32, the interface 32 continuing to advance until the stabilizing layer 30 is covered The entire precursor 28 is shown in FIG. The air bubbles formed between the precursor 28 and the stabilizing layer 30 are substantially minimized when the pressure applied by the stabilizing layer 30 advances.

As shown in FIG. 7, for example, by providing a mold upper cover 10a over the stabilizing layer 30, the mold 10 can be closed. When the mold 10 is closed, the precursor 28 can flow into all areas of the mold 10 defined by the gasket 20, including the individual molds 18 and chambers 18a, and any trapped air can pass through the opening of the sealing shop. 22 and exit the mold.

As shown in Figures 8 and 9, the precursor can be polymerized to form the polymer 29 within the closed mold 10 after a period of time (e.g., 30 seconds to 5 minutes). The molding process typically requires a pressure of 60 pounds per square inch, but as mentioned above, additional pressure, heat and/or vacuum can be applied to the process for different reasons, if desired. The different reasons for the mold are, for example, to increase the speed of the process, to improve the quality of the final material, to change the surface properties of the polymer, and/or to otherwise. As a result, the total processing time for manufacturing the plurality of molded products 19 can be greatly reduced as compared with other methods such as injection molding. Moreover, since the time to distribute the precursor 28 is reduced compared to other methods, the rate of curing can be increased by varying a number of factors such as pressure, temperature, catalyst concentration (when used), And/or others. When the article to be formed requires more definition (e.g., undercut and others), thermal energy, pressure, and/or vacuum may be used during the molding process as desired. When vacuum forming or thermoforming, the porous composite material can be at least partially formed by a mold as desired, so that complex details and surface patterns in the molded article can be formed. An example of such a porous synthetic material is breathable aluminum, which is a commercially available material under the trademark METAPOR ^(TM) .

After curing, the mold can be opened, and a plate 32 (showing a partial cut) containing the molded product 19 (in this example, a shoe inner pad) can be detached from the mold 10, as shown in FIG. Show. As shown, each of the molded products includes a plurality of pillars 21. As described above, the size, shape and contour of the column can be changed. Since the polymer 29 is compressed by the two layers 26, 30, the presence of the barrier layer 26 and the stabilizing layer 30 makes the plate 32 easy to handle, which is an advantage, otherwise the polymer 29 is adhesive. Properties such as polymeric gel materials result in the polymer sticking to the surface, such as the surface of the mold, the hands of the user, and others. The plate 32 includes a plurality of relatively thin regions 29a disposed between the pillars 21 and interconnected with the pillars 21. The region 29a may comprise polymer thickness "T _1", and the depth D of the recessed region 16 of _a mold 10, respectively. In order to minimize waste, or when it is desired to make the thickness of the region 29a as thin as possible, the depth D _{1 of} the recessed region 16 can be selected to be as small as possible while still leaving the precursor 28 unrestricted. The area defined by the gasket 20 is advanced. Thus, the thickness of the region 29a be minimized, so that the thickness T ₁ may comprise slightly more than the thickness of the insulating layer and the stabilizing layer are combined, as shown in Fig.

The molded product 19 can be cut (e.g., die cut and otherwise) by passing through the barrier layer 26, the polymer region 29a, and the stabilizing layer 30, and the plate 32 is separated from each other. The molded product 19 can be die cut between the polymer regions 29 and 29a and/or through the polymer region 29. When the polymer 29 is tacky, it can be die cut as desired through a portion of the polymer region 29 adjacent the polymer 29a such that the sides of the molding unit 19 comprise exposed areas of the polymer. Otherwise, the exposed edges of the regions 29a are sufficiently thin when not needed or necessary to avoid minimizing the edges of the product 19 and piercing adjacent surfaces. During the die cutting, the stabilizing layer 30 is present to avoid shrinkage of the polymer 29 and the barrier layer 26, or to minimize shrinkage, thereby substantially maintaining the molding as compared to the size of the die unit 18. Product 19 size. Since the shrinkage of the molded product 19 can be minimized, it is not necessary to take the shrinkage as a factor into the design of the mold, and when other methods are used, it is necessary to factor the shrinkage as a factor in the design of the mold.

Alternatively, layers 34 of the same or different materials (see FIG. 16) may be disposed between the aforementioned layers, for example, between the stabilizing layer 30 and the polymer 29, and/or the polymer 29 and the spacer layer 26. between. Also optionally, layer 34 may be disposed within region 29, for example, by providing a first portion of the precursor 28 on the spacer layer 26, and then placing the layer 34 over the first portion of the precursor 28, A second portion of the precursor 28 is disposed over the layer 34. Layer 34 can comprise a wide variety of synthetic and/or non-synthetic materials including, but not limited to, paper, fabric, plastic film, metal foil, and/or the like, along with a composite comprising at least one of the foregoing materials and / or composition. When layer 34 comprises a layer of fabric, the fabric may be a knit, woven, non-woven, man-made, non-artificial, and a composition comprising at least one of the foregoing. Since it can capture air bubbles otherwise formed within or between the layers, it is beneficial to provide the fabric layer as layer 34, resulting in a better appearance of the final molded product 19. Layer 34 can also include colors, graphics, and/or indicia, including text. When the other layers are composed of a colorless and/or transparent material, the colors, graphics, and/or indicia disposed on the layer 34 can be transmitted to other layers, which may be aesthetically pleasing and cost effective. Additionally, layer 34 can be fluid permeable when needed. As used herein, "fluid permeable" means that the material forming layer 34 is open to a passage or inlet of a fluid material, such as the precursor.

Likewise, layer 34 can be selectively used in place of the stabilizing layer 30. When layer 34 replaces stabilizing layer 30, layer 34 may apply the same elements described above with respect to stabilizing layer 30.

In some instances, it is described that the molded product 19 can be adhered to different surfaces. Thus, an adhesive (not shown) can be selectively disposed on one or more surfaces of the final molded product 19. Likewise, an adhesive can be selectively disposed and/or on one or more of the layers 26, 28, 30, and 34. For example, with respect to Figure 11, an adhesive can be disposed on surface 30b and the adhesive can be supported by a release and/or support layer (not shown). Some possible adhesives include pressure sensitive adhesives, thermoplastic adhesives, and others, along with compositions comprising at least one of the foregoing materials. An example of a suitable adhesive comprises the product number 7026 sold by 3M.

In some instances, the polymer 29 can comprise sufficient adhesion strength to adhere to a surface in the absence of a separate adherent. In this example, the stabilization layer 30 can be manually removed from the polymer 29. Accordingly, the stabilizing layer can optionally include a release coating layer (not shown), such as silicone, disposed on surface 30a to assist in manually removing the stabilizing layer 30 from the polymer 29.

Various types of materials can be used in the foregoing method to manufacture the aforementioned molded product 19. The barrier layer 26 can comprise any material that provides sufficient elasticity to avoid tearing and/or stretching when force is applied thereto; has sufficient structural integrity to be formed into a predetermined shape; and can withstand use in a given environment Without substantial attenuation. The barrier layer 26 can also be selected such that the polymer layer is easy to handle, and the polymer layer can include adsorptive properties in certain instances. Thus, after molding, the barrier layer 26 can be selected to include a relatively non-tacky surface and a relatively smooth feel of the human touch. Some possible materials of the barrier layer 26 include polyolefins, polystyrenes, polyvinyl chloride (PVC), latex rubber, and thermoplastic elastomers (TPEs), and/or Others, and compositions comprising at least one of the foregoing materials. Some possible TPEs materials include polyurethanes, silicones, and/or others, and compositions comprising at least one of the foregoing materials. The barrier layer 26 can comprise an elongation of from about 100% to about 1500%, more specifically from about 200% to about 1000%, and still more specifically from about 300% to about 700%. When the term "about" is understood, it is used to connect the quantity containing the recited value and has the meaning indicated by the context (eg, including the degree of error with respect to measuring the particular magnitude). Other possible materials for the barrier layer 26 include, but are not limited to, fabrics, paper, plastics (eg, polyester, polyethylene, polyvinyl chloride (PVC), and others), metal, metallization Plastic, and/or other, and compositions comprising at least one of the foregoing materials.

The barrier layer 26 can comprise any thickness that enables the molded product to not adhere to the mold. The thickness of the spacer layer 26 can vary depending on the application and the desired thickness, and the desired thickness for a particular application can be determined by routine experimentation as is known to those skilled in the art. The thickness of the barrier layer 26 can range from about 0.2 milliTorr to about 60 milliliters, more specifically from about 0.5 milliliters to about 30 milliliters, and still more specifically from about 1.0 milliliters to more specifically. About 15 millimeters. For example, an example of a product that can have a relatively thin barrier layer to achieve a touch that emphasizes the hand has been found. Therefore, such products can be used as required without the need to sacrifice the thinnest barrier of durability. For example, a preferred embodiment of the relatively thin barrier layer 26 may comprise a thickness ranging from about 0.2 milliliters to about 6 milliliters, more specifically from about 0.5 milliliters to about 3 millimeters, and yet More specifically from about 0.6 milliliters to about 2 milliliters. When it is determined that the hardness of the layer 29 formed by the polymerization is so viscous, when the barrier layer is pierced, the viscous material is exposed, making the product difficult to handle. In this example, a thicker isolation layer 26 can be used, which provides increased durability compared to a thinner isolation layer. For example, when the present material is used in an application example of vibration suppression, the thickness of the spacer layer 26 may be required to be from about 50 millimeters to about 60 millimeters. When the product is formed using a thermoforming process, it may be desirable to use an isolation layer of up to about one-eighth inch thick, and some instances may even be thicker when required or necessary. It has been found that the introduction of heat or vacuum during the thermoforming process may maintain a very soft flexibility of the barrier layer having a thickness of 6 millimeters or more.

As described above, the spacer layer 26 can be applied as a plate material during molding. The shape of the sheet, particularly when the barrier layer is relatively thin, can be very elastic during handling and can create creases and/or be easily bent. Thus, the isolation may also include a support layer (not shown) that assists in the disposal of the material. When the spacer layer 26 comprises such a support layer, the support layer may be disposed adjacent to an upper surface of the mold, the spacer layer material facing the upper surface and away from the upper surface, as required or necessary, in the mold Remove it before cutting.

As described above, when the spacer layer is not made of a plate material, the spacer layer can be applied as a coating material during or after the molding process. When the material is applied after the molding process, the spacer layer may be disposed on the precursor after the molding of the molded unit 18 is completed. For example, the molded unit 18 may be manually painted, sprayed, or brushed. Formed and/or otherwise formed. When the spacer layer 26 is not applied as a sheet material or a coating material during molding, and the precursor 28 may be directly disposed on the upper surface 12 of the mold 10, above the upper surface 12 A release agent is required.

The polymer 29, 29a may comprise any polymeric material comprising sufficient structural integrity to be formed into a predetermined shape, including a foamed polymeric material and a foamed expanded polymeric material; and the polymer is capable of withstanding use in a given environment without Great attenuation. The hardness of the material (e.g., the polymeric material) can be selected to provide the article and/or the region of the article has a predetermined hardness that can be trimmed for a particular cushioning and/or mold-resistant application. The polymer 29, 29a may comprise a hardness value from about 30 Shore hardness tester type 000 to a Shore hardness tester D type of about 88. The hardness of the polymer can be determined by an instrument known to those skilled in the art using, for example, a durometer or a penetrator.

Examples of suitable polymeric materials include, but are not limited to, thermoset polymeric materials, elastomeric polymeric materials, thermoplastic materials, including thermoplastic elastomeric materials, and compositions comprising at least one of the foregoing materials. Some possible polymeric materials include, but are not limited to, polyurethanes, silicones, and/or the like, and compositions comprising at least one of the foregoing materials.

的聚胺基甲酸酯泡沫發泡體。Examples of other materials include (but are not limited to) synthetic materials and others. A suitable material is commercially available PORON

Polyurethane foam foam.

The precursor 28 can be formed by a variety of methods known to those skilled in the art. For example, the shaping of the polyurethane gel may comprise a suitable prepolymerized precursor material that acts as a chemical reaction, such as a chemically reactive polyol and isocyanate in the presence of a catalyst.

In certain instances, the polymer may be required to have sufficient softness and/or flexibility to provide comfort to the polymer against the body. In such an example, the polymer may comprise a hardness value from about 0.01 Shore hardness meter 00 to a hardness value less than or equal to about Shore A type A of about 70, and more specifically less than Shore hardness meter 00. The hardness value of the type 70, more specifically, is less than the hardness value of the Shore durometer 00 type 60.

In certain embodiments, the polymer may be required to have sufficient adhesive strength to adhere to a selected surface (e.g., the inner surface of the shoe) that will dispense with adhesion to the desired surface of the molding unit. The demand for adhesives. It is possible to change the adhesion strength of the polymer by, for example, the hardness of the material used to form the layer. In such examples, the polymer can comprise, for example, a polymer having a Shore hardness tester type of about 30 hardness values to a Shore hardness meter type 00 of about 85 hardness values. The gel material at this relatively low hardness range may contain a consistency like jelly. One possible material having this adhesive property is a polyurethane gel which contains a hardness value of about 50 for Shore hardness meter 00 to a hardness value of about 70 for Shore hardness 00 type, which provides sufficient adhesion. The strength is adhered to the desired surface, such as the surface inside the shoe, or a rigid plastic such as polypropylene.

Again, although a polymer is shown herein, other materials, such as synthetic materials, may be used to form the layers and/or regions 29, 29a.

The polymer 29 and/or the barrier layer 26 may comprise one or more additives such as, but not limited to, modifiers, toners, stabilizers, phase change materials, UV inhibitors, and/or An active agent, and a composition comprising at least one of the foregoing materials. The concentration of the additive can vary depending on the desired effect of the agent.

One possible phase change material may comprise phase change microspheres (sold under the product name Outlast) that contain materials that are phase changeable at near body temperature. As a result, thermal energy can be stored in the barrier layer to produce a product that can feel cool or warm.

Suitable active agents may include tolnaftate, undecenoic acid, allylamines, chlorine, cooper, baking soda, oregin sodium. (sodium omadine), zinc omadine, azoles, silver, and/or the like, and a composition comprising at least one of the foregoing materials. For example, silver provides an antifungal/antibacterial effect. For economic and performance purposes, it has been found to be beneficial to include the active agent in the barrier layer when in use. Since the separator 26 is relatively thin compared to the polymer 29, the active agent is disposed in the separator, and the total amount of the active agent used is reduced, which is equivalent to the other thicker layers. Concentration, thus reducing the costs associated with the active agent. Again, the active agent is disposed in the barrier layer 26 to ensure that the active agent is disposed in the outermost layer of the article, i.e., in contact with the body, rather than from the user, thereby increasing the effectiveness of the active agent.

In some instances, a colorless material may be required for each of the barrier layers, polymer, and stabilizing layers, which may be aesthetically pleasing. In another embodiment, when layer 34 is included in the structure, and the layer includes color, graphics, and/or indicia, because the color, graphics, and/or indicia can be seen through the plurality of layers, the multi-layer can also be required to be colorless and / or transparent material.

)。在其他實施例中，穩定層30可包含自約1毫米(millimeter,mm)至約8毫米的厚度範圍，更特定地自約2毫米至約6毫米，且又更特定地自約3毫米至約4毫米的厚度範圍。具前述厚度範圍之可能材料，是商業上可獲得的以PORON

為名的聚胺基甲酸酯發泡體。The stabilizing layer 30 can comprise a material that can substantially reduce the shrinkage of the barrier layer 26, the precursor 28, and/or the polymer 29 during and after the process; it can provide support for the polymer 29; The polymer 29 and the separator 26 are easily handled. The stabilizing layer 30 may comprise any material that is substantially inelastic compared to the polymer 29 during and after the process and in order to be able to provide stability of the plate 32 and/or the dimensions of the molded product. Some possible materials for the stabilizing layer 30 include, but are not limited to, fabrics, paper, plastics (eg, polyester, polyethylene, polyvinyl chloride, and others), metals, metallized plastics, and/or others. A composition comprising at least one of the foregoing materials. The stabilizing layer 30 can comprise any thickness as desired for a particular application, the thickness of which can be determined by those skilled in the art. For example, in certain embodiments, the stabilizing layer 30 can comprise a range from about 0.2 milliTorr to about 10 milliliters, more specifically from about 0.5 milliliters to about 5 milliliters, and still more In particular, it ranges from about 1 mil to about 2 mil. A possible material with the aforementioned thickness range is oriented polyester film, which is obtained from a variety of commercial sources and products of various brands (eg MYLAR)

). In other embodiments, the stabilizing layer 30 can comprise a thickness ranging from about 1 millimeter (mm) to about 8 millimeters, more specifically from about 2 millimeters to about 6 millimeters, and still more specifically from about 3 millimeters to A thickness range of about 4 mm. Possible materials with the aforementioned thickness range are commercially available as PORON

Named polyurethane foam.

The foregoing methods and materials may facilitate the manufacture of polymeric articles and/or areas of articles that may require aesthetics and/or minimize wear and/or friction. Such methods can be used to shape the polymeric article and/or the region of the article, including any size, thickness or geometry. The size, thickness, geometry, softness, and adhesion strength of the article and/or portions of the article can be selected to optimize the design conditions. Examples of such useful polymeric materials include, but are not limited to, handles for personal care products, such as hairbrushes, toothbrushes, and razors; medical devices such as masks, crutches And corrections; handles for household items such as brooms, luggage straps, backpacks, briefcases and purses; clothing such as bicycle shorts, shirts and shoes; for example, mouse pads, keyboard cushions; handles and/or straps for retail merchandise, For example, bottles and/or boxes, laundry detergents; sports goods and accessories, such as racket grips, bat grips, fishing rod grips, guns and pedal riders; and others. In addition, the article can include indicia such as colored labels, text and/or drawings, and others.

英吋的厚度範圍，但是當可理解其他厚度可使用本方法而達成，其將取決於應用例。一隔離層26可被設置於鄰近聚合物層29，且穩定層30可被設置於該隔離層26對面的該聚合物層29的一側。當有需要時，鞋裡內墊40可包含活性劑，例如一抗真菌劑，其設置於該隔離層26中。在一說明實施例中，該隔離層26可包含一活性劑，例如銀，以預防且/或治療運動員腳的情況。可能的隔離層26包含可自Omniflex公司獲得Vacuflex 18411 AG這樣的活性劑。Figures 13-14, when combined, display an exemplary in-shoe inner pad 40 that can be formed using the methods and materials previously described. The insole inner pad 40 can include upper and lower surfaces 40a, 40b. In the illustrated embodiment, the insole inner pad 40 can comprise from 0.02 inches to

The thickness range of the inch, but when it is understood that other thicknesses can be achieved using the method, it will depend on the application. An isolation layer 26 can be disposed adjacent the polymer layer 29, and the stabilization layer 30 can be disposed on one side of the polymer layer 29 opposite the isolation layer 26. The inner liner 40 can include an active agent, such as an antifungal agent, disposed in the barrier layer 26 when desired. In an illustrative embodiment, the barrier layer 26 can comprise an active agent, such as silver, to prevent and/or treat the condition of the athlete's foot. Possible barrier layer 26 comprises an active agent such as Vacuflex 18411 AG available from Omniflex.

In another embodiment, the polymeric layer 29 can comprise sufficient adhesive strength to adhere to a surface, such as the inner surface of a shoe. Accordingly, the stabilizing layer can optionally include a release coating layer (not shown), such as silicone, disposed on surface 30a that can assist in manually removing the stabilizing layer 30 from the polymer 29, thereby exposing the The polymer 29 is adhered to a surface.

In another embodiment, an adhesive (not shown), such as a pressure sensitive adhesive, may be disposed on the surface 40b of the stabilizing layer 30 such that the insole inner pad 40 adheres to a surface, such as the inner surface of the shoe. This option may be useful, for example, when the stabilizing layer does not comprise a release coating on surface 30a.

Figures 15-16 illustrate an exemplary strap 50 that can be formed using the methods and materials previously described. In the illustrated embodiment, the strap 50 can include a spacer layer 26 disposed adjacent the first polymer layer 29, a fabric layer 34 disposed on one side of the polymer 29 opposite the barrier layer, and the stabilization layer 30 disposed adjacent thereto. Fabric layer 34.

As noted above, layer 34 is at least partially fluid permeable which allows the precursor to penetrate at least a portion of layer 34 (e.g., a woven textile strand). Thus, during the molding process, when layer 34 is fluid permeable, the precursor can at least partially flow through layer 34 or a portion of layer 34, and at the side of layer 34 opposite the polymer layer 29. A viscous adhesive surface is created, the surface of which may be a continuous or discontinuous layer, depending on the amount of precursor flowing through layer 34. Thus, in the final product, layer 34 is sandwiched between two layers of gel that are at least partially interconnected. It will be understood that the extent to which the gel penetrates into and/or through layer 34 depends on various factors including, but not limited to, the type of material, the thickness of the material, the extent of fluid permeable material (eg, The size of any pores and/or openings in layer 34, and others, the viscosity of the gel, the pressure and temperature of the molding, and others. Therefore, the thickness of layer 29a, and whether the layer is continuous or discontinuous, also depends on the foregoing.

As described above, the adhesion strength of the layers 29, 29a may vary depending on various factors. In one embodiment, when the polymeric layer 29a has sufficient adhesive strength, it can be used to adhere directly to the surface of the strap 50, such as the inner surface of a tote bag (not shown), thereby eliminating individual Adhesive. In another embodiment, an adhesive (not shown) may be disposed between the polymer layer 29a and the stabilizing layer 30 when needed. The strap 50 can be placed in the shoe (not shown) by peeling back and removing the stabilizing layer 30, exposing the adhesive polymer layer 29a, and adhering the polymer layer 29a to the strap 50. When desired, the belt 50 can comprise an antifungal agent disposed within the barrier layer, such as the foregoing examples.

In any of the foregoing embodiments, the use of a layer 34 of color or pattern (e.g., a color-added and/or patterned fabric layer) in combination with a transparent polymer can provide visualization of a polymeric article incorporating a color or pattern. Objects with more color variations can be produced than polymers that may only use color or pigment added. The use of a patterned fabric or metallic lustrous fabric or other aesthetically pleasing layer 34 imparts aesthetic appeal to the polymeric article; it may be difficult or not necessary to add the pigment to the polymer or to print the polymeric article. It is possible to give this polymer such beauty. This process also provides potential economic benefits.

The disclosed method may include one or more of the following advantages: 1) the method comprises forming the formed product with a plurality of pillars; 2) the individual pillars are capable of being compressed and are also movable to the left and right, which is applicable to Buffer and shock suppression are provided in various applications; 3) the thickness of the pillars and/or the spacing between the pillars may be trimmed to provide the desired characteristics of absorbing shock and vibration; 4) formable a product having varying thicknesses of pillars and/or spacing between the pillars; 5) using the pillar regions to make the overall cushioning lighter and compared to pillars made of solid polymer It is more flexible while still maintaining the thickness of the polymer necessary for buffering. 6) The relatively thin barrier layer and release layer used on the opposite side of the polymer layer allows the operator in the molding apparatus and equipment to process the lower hardness polymeric material without adhering to the equipment and/or the operator; Using a relatively thin barrier layer to reduce the total amount of additive used while reducing cost; 8) using a relatively thin barrier layer to enable relatively low hardness polymeric materials to be molded into different shapes, sizes, densities, and An article that is shaped to vary in size, shape, and density; 9) use of the stabilizing layer to reduce or eliminate shrinkage of the precursor, polymer, and/or barrier during and after the process; 10) when using polyamine In the case of urethane gels, this process provides colorless and transparent objects that do not turn yellow, such as typical polyurethanes that are exposed to UV energy.

The present invention is described with reference to an exemplary embodiment, and it is apparent to those skilled in the art that various modifications may be made without departing from the scope of the invention. In addition, various modifications may be made in accordance with the teachings disclosed herein without departing from the scope of the invention. Therefore, the present invention is not limited to the specific embodiments of the present invention, but the invention is intended to cover all embodiments within the scope of the appended claims.

10. . . Mold

10a. . . Upper cover

12. . . Upper surface

14. . . lower surface

16. . . Concave area

16a. . . region

18. . . Mold unit

18a. . . small room

18b. . . Base

18c. . . Side wall

19. . . Final molded product

20. . . Seal

twenty one. . . Column

twenty two. . . Seal opening

twenty three. . . Seal recess

twenty four. . . Nesting guide

26. . . Isolation layer

27. . . Roller

28. . . Precursor

29. . . polymer

29a. . . region

30. . . Stable layer

30b. . . surface

32. . . Plate

34. . . Floor

40. . . Inner cushion in shoes

40a. . . Upper surface

40b. . . lower surface

50. . . tape

D ₁ . . . depth

D ₂ . . . depth

R. . . Radius edge

P. . . Surrounding

T ₁ . . . thickness

T ₂ . . . thickness

T ₃ . . . thickness

W ₁ . . . width

W ₂ . . . width

The advantages, novel features, and uses of the present invention will be changed from the following detailed description of the embodiments of the present invention, which are not to More significant. In the figures, each identical or substantially similar component that is shown in the different figures is represented by a single number or annotation. For the sake of clarity, not every component in every drawing is labeled, nor is each component of every embodiment shown in the present invention indicated, and it is not necessary for those skilled in the art to understand the contents of the present invention. . In the picture:

1 is a perspective view of an exemplary in-shoe pad mold that can be used in accordance with the teachings of the present invention;

Figure 2 is a schematic cross-sectional view of the mold shown in Figure 1, through the line 2-2, showing a cut-away view of the inner mold of the two shoes;

Figure 3 is a schematic cross-sectional view of the mold shown in Figure 2, showing a barrier applied to the mold;

Figure 4 is a schematic cross-sectional view of the mold shown in Figure 3, showing a precursor applied to the isolation layer;

Figure 5 is a schematic cross-sectional view of the mold shown in Figure 4, showing a method of applying a stabilizing layer to the precursor, and advancing the stabilizing layer over the precursor;

Figure 6 shows the stabilizing layer covering the precursor;

Figure 7 shows the mold being closed;

Figure 8 shows the mold after shutdown and the polymerization of the precursor;

Figure 9 shows a developed view of a portion of the mold adjacent to the gasket after shutdown and after polymerization of the precursor;

Figure 10 is a side elevational view, partially in section, of the panel containing the interconnected inner liner of the shoe after the mold has been demolded and along the imaginary line;

Figure 11 shows a cutaway side view of the inner pad of the shoe shown in Figure 10 after die cutting to remove portions of the interconnected inner pad of the shoe;

Figure 12 is a developed view of the inner pad of the shoe for the portion shown in Figure 11, showing the edge portion of the inner pad of the shoe;

Figure 13 is a top perspective view of the inner cushion of the shoe of Figure 12;

Figure 14 is a side elevational view of the inner pad of the shoe of Figure 13, showing the removal of the stabilizing layer;

Figure 15 is a top perspective view of a tape made in accordance with the method of the present invention.

Figure 16 is a cutaway side elevational view of the inner pad of the shoe of Figure 13 showing the removal of the stabilizing layer.

twenty one. . . Column

30. . . Stable layer

40. . . Inner cushion in shoes

40a. . . Upper surface

Claims (41)

A buffer element comprising: a multilayer material comprising an isolation layer, a layer of polymeric material disposed adjacent to the isolation layer, and a stabilization layer disposed adjacent to and opposite the isolation layer; a plurality of pillars And the plurality of pillars comprise a thickness, an upper surface and a side wall extending downward from the upper surface and undercuting the upper surface a surface to form a radiused upper edge between the upper surface and the sidewall; a plurality of spacer regions disposed between the plurality of pillars, each of the plurality of spacer regions A spacer region thickness is included; wherein the pillar thickness is greater than the spacer region thickness. According to the cushioning member of claim 1, the thickness of at least two of the plurality of pillars is different. According to the cushioning member of claim 1, wherein at least two of the plurality of pillars are different in shape. According to the cushioning member of claim 1, the thickness and shape of at least two of the plurality of pillars are different. The cushioning member of claim 1, wherein the plurality of pillars have a thickness of less than about 3 inches and the plurality of spacer regions have a thickness greater than or equal to about 0.002 inches. The cushioning member of claim 1, wherein the plurality of pillars have a thickness of less than about 3 inches and the plurality of spacer regions have a thickness of less than or equal to about 0.250 inches. The cushioning member of claim 1, wherein the plurality of spacer regions have a width greater than or equal to about 0.002 inches. A cushioning member according to the first aspect of the invention, wherein the barrier layer is selected from the group consisting of a free fabric, a fabric synthetic material, a thermoplastic elastomer (TPE) material, and a composition comprising at least one of the foregoing materials. A cushioning member according to item 8 of the patent application, wherein the barrier layer is a thermoplastic polyurethane (TPU). The cushioning member of claim 1, wherein the barrier layer comprises an elongation of at least about 100%. The cushioning member of claim 1, wherein the barrier layer has a thickness of less than or equal to about 5 milli-inch. The cushioning member of claim 1, wherein the barrier layer has a thickness greater than or equal to about 5 milli-inch. A cushioning member according to claim 1, wherein the barrier layer comprises a water vapor permeable material. A cushioning member according to claim 1, wherein the barrier layer comprises a phase change material. The cushioning member according to claim 1, wherein the barrier layer comprises an active agent. A cushioning member according to claim 15 wherein the active agent is selected from the group consisting of an antimicrobial active agent, an antifungal agent, and a composition comprising at least one of the foregoing materials. The cushioning member according to claim 1 further comprising a layer of fabric material disposed between the layer of polymeric material and the stabilizing layer. The cushioning member according to claim 17, wherein the fabric layer comprises a knitted fabric, a woven fabric, a non-woven fabric, an artificial fabric, a non-artificial material, and a composition comprising at least one of the foregoing. The cushioning member of claim 1, wherein the at least one of the barrier layer and the stabilizing layer comprises a layer of fabric material having an elongation of at least 100%. A cushioning member according to claim 19, wherein the fabric material layer comprises a knitted fabric, a woven fabric, a non-woven fabric, an artificial fabric, a non-artificial material, and a composition comprising at least one of the foregoing materials. A cushioning member according to claim 19, wherein the layer of fabric material is fluid permeable. According to claim 1, the adhesive further comprises an adhesive disposed between the polymeric material layer and the stabilizing layer. The cushioning member according to claim 22, wherein the adhesive is disposed on a support layer. A cushioning member according to claim 23, wherein the support layer is a TPE material. The cushioning member of claim 1, wherein the stabilizing layer is removable from the cushioning material. A cushioning component comprising: a multilayer material comprising an isolation layer and a spacer layer disposed thereon Adjacent polymeric material layer, and a stabilizing layer disposed adjacent to and opposite the insulating layer; a plurality of pillars disposed within the multilayer material, each of the plurality of pillars including an upper surface And a sidewall extending downwardly from the upper surface to a spacer region and defining a radiused upper edge between the upper surface and the sidewall, and each of the plurality of pillars The article comprises a ratio of thickness to width which is greater than or equal to about 0.125 to 1. A cushioning member according to claim 26, wherein the ratio of the thickness to the width is less than or equal to about 8 to 1. A cushioning member according to claim 26, wherein the side walls extend substantially perpendicularly downward from the upper surface. A cushioning element according to claim 26, wherein the side walls undercut the upper surface. A method of molding a cushioning component, comprising: disposing an insulating layer over an upper surface of a first molding zone, the barrier layer comprising a thermoplastic elastomer (TPE) material having greater than or equal to about 0.004 inches a thickness of the crucible; the spacer layer is drawn toward the surface of the first molding region under the influence of a vacuum; a first portion of the precursor of the polymeric material is distributed on the spacer layer; and a stabilizing layer is disposed on the precursor Providing a second molding zone over the stabilizing layer; and curing the precursor to form a cushioning element as in claim 1 of the patent application, Wherein the polymer of the polymeric material is enclosed by the barrier layer and the stabilizing layer. The method of claim 30, further comprising heating the barrier layer prior to providing the spacer layer over the molding region. The method of claim 30, further comprising heating the barrier layer by heating a surface above the molding region. According to the method of claim 30, an adhesive material is disposed between the precursor and the stabilizing layer. The method of claim 30, wherein the TPE material comprises an active agent from silver, tolnaftate, undecenoic acid, allylamines, Chlorine, copper (cooper), sodium bicarbonate (baking soda), sodium omadine, zinc omadine, azoles, and at least one of the foregoing materials Selected from the group consisting of the compositions. The method of claim 30, wherein the TPE material is a group consisting of a thermoplastic polyurethane (TPU), a silicone, and a composition comprising at least one of the foregoing materials. Elected in the middle. The method of claim 30, wherein the polymerized material comprises a hardness value of about 30 from a Shore hardness tester type 000 to a hardness value of about 75 Shore A hardness meter type 00. A method of using a cushioning element molded according to the method of claim 30, comprising manually moving the stabilizing layer from the article In addition, and attaching the cushioning element to a surface. A cushioning member according to claim 1 wherein the polymer of the polymeric material is enclosed by the barrier layer and the stabilizing layer. A sheet of cushioning material comprising a plurality of cushioning elements of claim 1 wherein the pillars are disposed within the cushioning elements. A sheet according to claim 39, wherein the plurality of cushioning elements are interconnected by a multilayer material of the cushioning element of claim 1 of the patent application. A sheet according to claim 40, wherein the polymer of the polymeric material is surrounded by the barrier layer and the stabilizing layer.